Costamp HPDC
AGENDA 1 Company presentation 2 Product overview 3 Product comparison
PiQ 2 facts Established in 2011 • • Head Offices in Brescia (IT) ABOUT US • Part of Costamp Group since 2016 We develop cutting-edge simulation • Micro Enterprise software which blends the practical and Innovative Startup Company • theoretical knowledge gained from Member of the Technological • experience in the foundry. Hub of CSMT
OUR MISSION The simulation phase is a key moment in the die manufacturing process
OUR MISSION Simulation software should be easy to use , making it simple to share results The simulation with key project personnel. phase is a key It should simulate the process moment in the on a detailed level, keeping die manufacturing all variables in check , process assisting the designer in each phase of the development of the die.
OUR CORE BUSINESS Simulates the production scenario which the die will operate Castle meets these needs in, providing crucial information via 4 independent modules to ensure it is developed correctly. Castle is a software application created by PiQ² for the aluminium, zinc and magnesium alloy die casting process.
Allows the user to carry out a simulation of a single runner , in order to optimise a section or quickly assess alternative solutions. Simulates filling and solidification phases whilst taking air flow into consideration.
The 4 Castle independent modules allow for accurate simulation of die performance in all its operational This module simulates phases, providing the thermal behaviour comprehensible results of the entire die. that can be used to optimise output.
WHY CHOOSE CASTLE? PARTNER COMPATIBLE USER DUAL INVESTMENT IN DESIGN FRIENDLY PHASE Import, modify and Immediate results, export all leading guaranteeing Supporting Intuitive interface, Can accurately 3D formats a rapid return the designer easy to use simulate air (Step, Parasolid, IGES, on investment in making behaviour, showing SolidWorksTM, CatiaTM key choices both the flow and SolidEdgeTM, and many any air entrapment others)
OUR SIDE BUSINESS • CONSULTANCY in metallurgy and manufacturing processes of light alloys • TRAINING in metallurgy and manufacturing processes • PRODUCT DESIGN development and optimization • CUSTOM SOFTWARE DEVELOPMENT upon specific request • COMMISSIONED R&D on foundry-related technologies
OUR MARKET CUSTOMERS Italy, Austria, UK, Singapore, China, Japan, India, Romania, Brazil, Turkey, Germany DEALERS Italy, USA, India, Turkey, China, Hong Kong, Japan, Czech Rep. 81 software customers (June2019) 92 licenses (June2019)
OUR CUSTOMERS AL foundries
OUR CUSTOMERS AL foundries
OUR CUSTOMERS AL foundries
OUR CUSTOMERS AL foundries
OUR CUSTOMERS Diemakers
OUR CUSTOMERS Diemakers
OUR CUSTOMERS Zamak
OUR CUSTOMERS Zamak
AGENDA 1 Company presentation 2 Product overview 3 Product comparison
SIMULATION According to PiQ 2 vision, simulation is: a design tool a working method a verification tool
CRITICAL POINTS SIMULATION • High purchase and maintenance costs Critical points • High usage costs (skillness & complexity): Castle software was purposely bottleneck in the engineering developed to overcome typical department workflow critical points of simulation • Analysis timing typically, the simulation can be software. performed only once the runner design is completed • Simulation results the simulation does not take into account some well known phenomena that occur during the process
1 st step: think before designing… • Make a global setting evaluation before die design • Accurately calculate and predict the effective die performance on the machine • Evaluate the casting geometry, define the quality requirements and optimize the mold-machine system
Innovative software solution that combines mathematical concepts from fluid dynamic principles with experience gained in die manufacturing and the foundry.
Analysis and definition of casting and process • Geometry (3D or virtual) • Machine, plunger, shot sleeve • Die and casting alloy grades • Process parameters. • Quality goals (porosity/surface quality)
Die/process output & optimization • Optimized process parameters • PiQ 2 DIAGRAM analysis • Gating dimensioning • Suggestions in spoken language
CastleMIND can analyze and optimize the behavior of the air extraction system either through simple air vents, chill-vents or valves, to optimize venting sections, pressures and strokes.
MAIN FEATURES ASSISTS THE PERSONALISED ASSISTS THE DESIGNER MACHINE FOUNDRY DATABASES Assists and optimizes Enables any defect verified the dimension and shape in production to be identified Provides a complete of the gates and vents. as a result of the die, the modelling Suggests the optimum piston machinery or the process. service of a machine’s diameter and automatically Helps to maintain casting equipment. fills out the machine quality. Assists in reducing parameters datasheet. die wear and metallization phenomena.
2nd step: optimize the runners, before simulating… • Optimize the geometry upstream of the gatings to avoid problems in the casting • Evaluate the effective behaviour of the channels • Compare different runner/gatings solutions in a few minutes
Innovative tool for the simulation of the flow in the runners . Allows the die maker to ensure the optimum geometry for the channel without carrying out the entire simulation of the model. Allows for the effective testing of various solutions to achieve the desired results.
• Run slow shot only simulation to check alloy behaviour or optimize slow shot speed and strokes • Early detect in runner or in shot sleeve air entrapment Typical calculation time: tenth of minutes
MAIN FEATURES STEADY STATE TRANSITORY, TWO-STAGE CALCULATION CALCULATION Provides a complete map The software allows the operator of flow pressure and to optimize the first speed which helps to identify phase speed profile to reduce the trajectory of metal air entrapment, and to flow, any turbulent flow, define the optimum settings gates which aren’t working for the start of the second as expected, air entrapments phase for a more uniform filling and bottlenecks. of cavities.
3 rd step: simulate the actual filling… • Specifically designed tool for HPDC • Maximum operator time reduction • Intuitive user interface • Hybrid mesh • Overcomes the weaknesses of the current software solutions
Dual-phase solution : simulates the combined action of a liquid (metal) and a gas (air), two elements with very different behaviour and density. Prepares the mesh calculation and sets up the simulation in a few minutes from any kind of geometry.
What’s the amount of air entrapped in a die cavity? Example: 2,7Kg aluminum casting weight (1L) 50 % shot sleeve filling ratio about 1 litre air in the shot sleeve about 1 litre air in the die cavity 2 litres air compressed at 1000 bar = 2 cm 3 porosity
Goal: correct metal/air interaction modelling • Simulate the effect of metal spraying caused by the speed and the impact of the fluid against the air • Consider the flow of both metal and air • Physically simulate the effect of vacuum and air vents and evaluate their performance
Goal: simulate correctly the behaviour of the liquid, taking into account heat loss • Realistic simulation of the metal flow • Take into account the characteristics of the fluids
CastleBODY Dual phase simulation software Air, liquid metal and their emulsion can be modelled simultaneously . The behaviour of the air flow during filling can be simulated so that even the smallest air entrapments can be identified, avoiding blisters and surface defects, to optimize the shape, section and design of the ventings as well as the injection profile.
CastleBODY Dual phase simulation software The simulation can show the difference between: • No air vents • Passive chill vents • Active vacuum When the liquid metal reaches the air vents, they get occluded and air cannot escape anymore.
CastleBODY Dual phase simulation software This technology allows to evaluate the interaction between shrinkage and gas porosity.
MAIN FEATURES HYBRID PARALLEL SOLIDIFICATION MESH CALCULATION SIMULATOR The internal mesh is made up It’s possible to launch Allows the user to take into of regular hexahedrons, whilst calculations in parallel account potential interactions elements close to the surface on multiple processors, between the porosity generated are adapted in order to replicate exploiting 100% of CPU during filling and the ones the exact original CAD geometry. performance. deriving from the solidification The mesh can be refined This represents a significant process. in localized, more intricate areas. time saving .
4 th step: simulate the thermal cycles… There are two types of simulations: • Simulation with implicit or virtual die (casting only) • Simulation with real die (modeling the die parts)
An innovative approach for the realistic simulation of the thermal behaviour of the entire die.
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